In the world of packaging, sustainability is often discussed in terms of materials, recyclability, and waste reduction. However, one of the most overlooked sources of waste in the packaging ordering cycle is custom samples. While these samples can be essential for some projects, they are often produced unnecessarily, contributing to excess material waste.
Are Custom Samples Really Necessary?
Custom samples often generate a significant amount of waste because the setup process for any packaging order requires fine-tuning. Each project has unique specifications, and getting everything aligned—printing, cutting, and material adjustments—is a process that inevitably causes waste. Since sample runs are so small, the percentage of waste relative to the total output is much higher than in full-scale production. This means that while custom samples serve a purpose, they also contribute disproportionately to material and resource waste.
Not all packaging projects require custom samples. For simple designs—where structural integrity and functionality are well understood—creating a unique sample may not be needed. Yet, many brands request them by default, without considering the environmental impact. Custom samples require energy, raw materials, and logistics to produce and ship, adding to the carbon footprint of the packaging process.
When Do Custom Samples Make Sense?
There are situations where custom samples are indispensable. If your project involves:
-
Complex designs or intricate features that require validation before full production.
-
Testing new materials, such as barrier options for moisture-sensitive or perishable products.
-
Ensuring functional elements, like closures or structural integrity, meet performance expectations.
In these cases, a physical sample can help fine-tune design specifications and avoid costly mistakes down the line.
A Smarter Approach to Samples
Before requesting a custom sample, consider these alternatives:
-
Digital Proofing & 3D Renderings – Modern packaging technology allows for highly detailed digital proofs and virtual mockups, which can provide an accurate representation of the final product without physical materials.
-
Printing & Existing Samples – Many people request custom samples to see how their colors appear, how multiple colors interact, or to assess text size. Instead of producing a new sample, we offer existing samples showcasing different artwork and print options. We can also recommend font sizes and, for materials like kraft paper, use drawdowns and Pantone matching to ensure color accuracy before printing. Additionally, we have many samples of standard sizes, closures, and special features from past orders that we'd be happy to send you.
-
Sustainable Sample Practices – If a sample is necessary, let’s first go through our existing sample options to ensure we have all the details as close to perfect as possible. This way, we can minimize the need for multiple sample runs and reduce unnecessary waste.
Reducing Waste, Retaining Quality
Being mindful of the need for custom samples is a small but meaningful step toward reducing waste in packaging production. By carefully assessing whether a sample is truly needed and exploring existing alternatives, brands can minimize their environmental impact while still ensuring quality and functionality.
Next time you’re considering a custom sample, ask: Is it truly necessary? Or could an existing sample or digital proof meet your needs just as effectively? Making informed choices in packaging doesn’t just save resources—it moves us all closer to a more sustainable future.